Differential - Electric Locker
DIFFERENTIAL-ELECTRIC LOCKER
REMOVAL
1. Remove lubricant fill hole plug from the differential housing cover.
2. Remove differential housing cover and drain the lubricant from housing.
3. Remove axle shafts.
4. Cut sensor wire tie strap (4) from adjuster lock.
5. remove sensor target magnet (1) from bearing cap.
6. Remove adjuster lock bolts (3) and adjuster locks (2).
7. Remove electric locker connector (1) retainer (2) bolt from differential housing.
8. Remove connector (1) and retainer (2) from differential housing.
9. Remove retainer (1) from connector and remove o-ring (2) from connector.
10. Mark bearing caps (2) left and right for installation reference.
11. Remove bearing cap bolts, anti rotation bracket and remove bearing caps (2).
12. Loosen differential bearing adjusters (3) with Spanner Wrench 8883.
13. Slid electric locker connector through differential housing.
14. Remove differential case with bearing cups from the housing.
15. Tag bearing cups left and right for installation reference.
DISASSEMBLY
NOTE: Internal differential components are serviced with the case.
1. Remove differential case bearing.
2. Remove coil (1) mounting bolts (2).
3. Remove coil (1) with sensor (2) and harness.
ASSEMBLY
NOTE: Internal differential components are serviced with the case.
1. Position coil on differential case (1) mounting location (2).
2. Clean coil bolts then apply Mopar(R)Lock & Seal adhesive to the threads
3. Install coil (1) and bolts (2).
4. Install differential bearing (1) with Handle C-4171 (2) and Installer 8956 (3).
INSTALLATION
1. Clean the housing cavity with a flushing oil, light engine oil or lint free cloth.
2. Lubricate differential case bearing.
3. Install differential case with bearings cups into the housing.
4. Slide electric locker connector through differential housing.
5. Install o-ring (2) on electric locker connector.
6. Install electric locker connector retainer (1) and install connector with retainer in differential housing.
7. Install connector retainer bolt.
8. Install bearing caps (2), anti rotation bracket and bolts. Tighten bearing cap bolts finger-tight.
NOTE: Do not torque bearing cap and bolts at this time.
9. Slide differential case toward the pinion gear until the gears make contact/zero backlash. If zero backlash cannot be obtained, turn the pinion side adjuster until zero backlash is obtained.
10. Holding the differential case toward the pinion gear, turn bearing adjusters with Spanner Wrench 8883 until they make contact with the differential bearings/cups.
11. Back off the ring gear side adjuster 4 holes, to obtain initial ring gear backlash.
12. Install ring gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
13. Tighten pinion gear side adjuster firmly against the differential case bearing cup.
14. Rotate the pinion several times to seat the differential bearings.
15. Loosen pinion gear side adjuster until it is no longer in contact with the bearing cup.
16. Tighten pinion gear side adjuster until it just makes contact with the bearing cup.
17. Tighten pinion gear side adjuster an additional:
^ New Bearings: 6 Adjuster Holes
^ Original Bearings: 4 Adjuster Holes
18. Install pinion gear side adjuster lock and bolt. Do not tighten adjuster lock bolt at this time.
19. Tighten bearing cap bolts (4) to 165 Nm (122 ft. lbs.).
20. Tighten adjuster (2) lock bolts (3) to 25 Nm (18 ft. lbs.).
21. Measure ring gear backlash and check gear tooth contact pattern.
22. Install axle shafts.
23. Install sensor target magnet (1) on bearing cap.
24. Energize locker and rotate axle shaft. Verify dog clutch is engaged by rotating one axle while holding the other. If engaged axle will not rotate.
25. De-energize locker and rotate left axle 15 to 40 degrees so dog clutch gears will not engage.
26. Energize locker and set sensor air gap (2) to 5.5 mm ± 0.25 mm (0.21 inch ± 0.1 inch).
NOTE: System willtime out within 2 minutes, when key is in the on position and the engine is not running.
27. Tighten sensor target magnet bolt (3) to 7 Nm (62 in. lbs.).
28. Hold right axle and rotate left axle until dog clutch engages with an audible click noise.
NOTE: This will verfy the sensor air gap was adjusted with the dog clutch gears ear to ear.
29. Install sensor wire tie strap (4) in the original location or at white dot on wiring harness to the top leg of adjuster lock and de-energize coil.
30. Install differential housing gasket and cover. Tighten cover bolts to 40 Nm (30 ft. lbs.).
31. Fill differential with lubricant to specifications.
32. Install fill plug and tighten to 32 Nm (24 ft. lbs.).